400455 Fundamentals of Mechanical Engineering

Mechanisms Submodule (weighting 25% of module or 5 credits equivalent)

Assignment Specification G.L.Cutler

Introduction

The assessment for the Mechanisms Submodule of 400455 takes the form of written course-work.
There is NO examination element.

The course-work consists of a Mechanism Development Report (MDR), which consists of a response
to a design brief for a simple mechanism to the extent of about 1500 words plus diagrams, graphics,
tables, materials lists etc.

There is a choice of topic for the MDR, given below. The report is an individual piece of course-work
and is subject to the usual regulations concerning unfair means and plagiarism. You should not for
example simply cut-and-paste artwork to your submission without proper source attribution and
referencing.

Ignorance of the regulations regarding the use of unfair means is not considered a defence in these
cases.

Requirements for Mechanism Development Report

There are six topics for the MDR; you are required to choose ONE. You will be given an outline
structure for the report below. The point is not to come up with a perfect detailed design for a
particular mechanism, but rather to show how you developed your ideas from a basic consideration
of the design brief, looking at the mechanics and simple physics of solving the problem, generating a
conceptual design which will fulfil the requirements of the brief, and considering the mechanical
constraints around a robust design solution; that is, ONE WHICH WOULD ACTUALLY WORK.

To be clear, this is not about thinking of numerous different “creative” solutions – although you will
see in future that there is a definite place for such methods in conceptual design selection as part of
the larger design process. Neither is this an exercise in artistic skill or the use of CAD software (which
is assessed elsewhere). (On the other hand, if you are adept at CAD, please use it).

However, you will be expected to communicate your design intentions clearly and unambiguously in
the report, and as such it will be expected that you will be able to draw simple schematic diagrams
either by graphics software or more traditional methods. The emphasis is on thinking rather than
“glossy” presentation. It is also very important that you consider “real world” constraints on the
mechanism in practice, such as the effects of friction, or the vulnerability of the components to
corrosion in the operating environment.

Another important element is that you try to specify the components and materials for your
mechanism in a pragmatic way. This includes the use of standard parts such as bearings, belts or
gears which can be selected from online sources or even local suppliers if appropriate.

It is important that you describe clearly, with the assistance of diagrams, exactly how your
mechanism works. That is, the dynamics of the device is important – how it goes from one state to
another, achieving the task required, from beginning to end.
List of Topics for the MDR

These topics are deliberately Low-Tech. In each case the physics is simple enough that you should be
able to rapidly understand what the mechanism has to achieve – the work it has to do, the forces it
may be subjected to in use, etc. The emphasis is on producing a complete, workable solution. This
should be achievable in 40 hours or less of individual work, including write-up. Hopefully you may
even enjoy the process…

1. Produce a design for a lifting platform for a wheelchair user weighing 100Kg to allow them
to negotiate a 600mm high step up to a raised patio area in their garden. (There is
insufficient space for safe ramp). As there is no electricity available, the platform must be
self-powered by use of the arms (the client has full upper body mobility and average
strength – capable of exerting a force of 200N). There is no specific time constraint on the
completion of the raise, although at all times the platform must remain level and the chair
secure on it (unable to roll off).

2. Produce a human-powered band-saw for use in the woodcraft industry in the developing
world, to rough-out wooden blanks for skilled carvers of ornaments. As the workpiece has to
be manipulated by hand while sawing, you may assume that power is derived from the legs
of an able-bodied operator. The target speed of the blade is 8 metres per second, and you
may assume the operator can comfortably generate 200 watts with leg power while using
the device.

3. Green Kitchens Inc. (USA) produce a range of equipment for the environmentally-conscious
which use no electrical power. Their latest idea is for a bread-mixing device for the busy
home-maker which is capable of producing 3Kg of bread-dough in a single batch so as to
maximise the use of oven heat to produce several loaves. They have noted that electrical
devices capable of such a feat require a 350W motor, although perhaps environmentalist
users would tolerate a longer process using an equivalent of 200W. Design a heavy-duty
manual dough mixer for this client.

4. Garden-Gizmos Ltd have spotted a gap in the market for a device to pull out old fence-posts
or even small tree roots, to be used by a single worker on sites which are inaccessible to
vehicles. The brief is to develop a portable device in which no individual part weighs more
than 20Kg, but which is capable of exerting an upward pull of 20kN using an effort of 250N.
The load may be applied between -0.5 metre and +1.0 metre from ground level. The ground
where the device is used may be soft and require load spreading to avoid sinking the
mechanism.

5. Festive Fires Ltd supply catering equipment for large outdoor public events such as
Agricultural Fairs and extravagant private parties. Roast meat sandwich selling is popular at
such events, and this client has identified a need for a mechanism to allow 4 animals to be
spit-roast simultaneously so as to supply large crowds all day long with food. The
requirement is for 4 whole carcases of 1 metre length and weight 50 kg to be simultaneously
managed by a single cook, and allowing serving staff access to any of the roasts at any time.
Each roast must be physically separate to avoid possible cross-contamination issues from
undercooked products at different stages of preparation. Design a solution capable of
tolerating temperatures of at least 400 Celsius throughout.
 6. A garden-centre entrepreneur believes that there would be a market for a pedal-powered
“rotavator” in order to speed up the process of digging over large areas of (e.g.) vegetable
plots with a traditional gardener’s fork or spade. His logic is that generally people’s legs are
much stronger than their arms. These devices are normally powered by a small petrol motor.
Is this human powered device even feasible? If so, what would be the physical
characteristics of such a machine?

Structure of your Mechanism Development Report

Following is a suggested structure for your MDR. It is a 10-point plan, so to speak, but the sections
are not mandatory and you may choose to modify the mode of reporting as appropriate, and
bearing in mind the forgoing instructions. The figures in square brackets give an indicative mark
weighting for these aspects of the MDR.

Choose one of the challenges 1-6 above and then:

1. Developing the Brief

Expand on the brief by researching more about the particular context of the mechanism;
find out more about the scope of such devices; what are the requirements of users? What
do they expect the mechanism to do? How long should it last? What other devices are
available which affect the user’s expectations? What performance data can you find out
about them? Are there any constraints on the design of such devices, such as special
regulations or health and safety considerations? Ethical issues? [10%]

2. Mechanical Analysis
Investigate the basic physics and mechanics of the system requirements. Given that
mechanisms transfer energy or power by translation or rotation of components, what can
you figure out about the forces or torques involved? Do these dictate any particular
dimensional constraints in order to derive a mechanical advantage? Remember the safe
lifting limit for average humans is deemed to be about 250N, and therefore it is unlikely that
human powered devices can involve greater efforts than that. [15%]

3. Concept Design
Based on the information derived in 1 and 2 above, generate a working concept for your
machine; this is likely to be best achieved graphically by sketching, although sometimes
crude physical modelling can be helpful using simple materials such as card and tape, in
order to help develop 3 dimensional space models and understand the disposition and
interaction of components. Such 2- and 3-D modelling will often spawn new ideas and
improvements to concepts. Use of 3D CAD modelling is welcome though not mandatory.
[20%]

4. Subsystem Interaction
Consider your mechanism as a set of subsystems. Are there alignment issues between
components? Can smooth operation or reliability be influenced by such issues? If so, can
these sub-system interfaces be enhanced (for example by the use of flexible couplings). It is
a general rule that many of the failures in mechanical systems occur at the interfaces of sub-
systems. [10%]

5. Component Search and Selection

Having formulated an idea of what your design looks like (a so-called embodiment design),
 try to identify standard components which can be incorporated into your system. This task
has been made infinitely easier by the existence of on-line search engines and catalogues of
components hosted by specialist suppliers. Even “one stop shop” sites such as EBay or
Amazon have their uses. A second line of general suppliers is the like of Farnell and RS
Components. Beyond that there are numerous more focused traders in the field of bearings
and spur gears, for example. [10%]

6. Geometrical Stability
Identify any holding or positional fixing issues; how will your parts be fixed in relation to
each other? How will they be held securely? What fasteners or adhesives could you use? [5%]

7. Environmental Robustness
Does your mechanism need an enclosure? Will the ingress of water, dirt or other
contaminants from the environment affect it? Can these issues be solved by careful
component selection (such as sealed bearing races for example). [10%]

8. Operational Reliability
What materials should you use in order to give your mechanism the expected strength,
operational lifetime, and reliability. (Remember a one year operational lifetime is considered
a minimum for most mechanisms) [10%]

9. Servicability
Is your design easy to service or repair? If a component fails, is it easy to remove and replace?
Can sub-systems be removed or does the whole thing have to be taken to bits? [5%]

10. Sustainability Issues

What about disposal and recycling? Sustainable design is becoming increasingly important,
and therefore low environmental impact materials, or those which can be reprocessed or
otherwise re-used are to be favoured. [5%]

Please note that standard components recommended by your report must be fully described with a
reference to the source and any technical data which is pertinent to the operation of the mechanism.
You need not include descriptive data on standard components (other than graphics and headline
specifications/ dimensions) in the body of your MDR.

Submission Deadline

Your report (approx. 1500 words plus diagrams) must be submitted as a pdf format file via Canvas
400455 module site no later than 2pm on Friday 10th January 2020. All sketches must be clear and
annotated to explain the mechanism function.